Wabocrete FMV

ABSTRACT

An expansion joint for bridges and similar structures comprising an elastomeric sealing element, anchoring means gripping the sealing element and resin mortar connecting the anchoring means to the structure. The resin mortar is comprised of a mixture of ureide and epoxy resins and aggregate. The anchoring means has rods embedded in the resin mortar to distribute stresses therein.

This is a continuation-in-part of prior U.S. application Ser. No.174,457 filed Aug. 1, 1980, now abandoned.

The present invention relates to an expansion joint and moreparticularly to the use of a resinous composition and mechanicalanchorage means for fixing of a sealing element to a structure such as aroadway or a bridge deck. The new joint is suitable for joint movementratings of 2 to 8 centimeters. In temperate climates, this will allowuse of the joints for spans of 25 to 300 meters.

BACKGROUND OF THE INVENTION

An expansion joint is a small bridge over an expansion gap which isprovided between a bridge abutment and a bridge deck, or between twosegments of the bridge deck; the small bridge extends beyond the edgesof the expansion gap. The expansion gap has a width which changes withthe temperature of the structure, and the small bridge of the expansionjoint is constructed to adjust its width to accommodate the variationsin the width of the gap. The allowable variations in the width of theexpansion joint will be referred to herein as its movement rating.

The edges of the upper surfaces of the bridge deck, abutment, or otherroadway segments are not always in the same horizontal plane, and theycan vary as traffic moves over the structure. These variations can be0.5 cm or more.

The expansion joint and its anchorage should be constructed to adapt tothese conditions, and to resist the effects of traffic, particularlythat of heavy vehicles, which are especially destructive when the top ofthe expansion joint is set at the same level as the roadway.

Various types of expansion joints have been used or proposed. They canbe summarized as follows:

The components constituting the mini-bridge can be either a slidingmetal element, for example, in a finger joint or a sliding plate joint,or an elastomer joint, or an elastomer honeycomb joint.

The various sliding elements or elements of variable width are fastenedeither directly or by metal elements, to the roadway of a bridge or toan abutment.

The anchorage itself generally comprises metal bolts fixed in theconcrete of the roadway, or rods buried in the concrete. This involveslong and delicate work because of the tolerances on the order ofmillimeters may be required in concrete work, and it is burdensomebecause of the small amounts of material used at the time ofinstallation of the joint in a previously constructed concrete roadway.

It has been proposed to use thermosetting resins to remedy thesedrawbacks. For example, it is known to use thermosetting resins toanchor the bolts in concrete. Others have used thermosetting resins tomake the edges of the joint, to avoid their erosion by traffic. Also,others have made more advanced proposals such as in French Pat. No.71/43,203, in which a joint comprising metal slides is simply glued tothe roadway structures using resins; this eliminates the need forconcrete when joints are installed in a previously-constructed roadway,and thus the problem of supplying small amounts of concrete at the siteat that time and the problems caused by slow setting of concrete.

The last-mentioned joint does indeed eliminate fatigue problems. On theother hand, problems arise because of the difference between theexpansion coefficients of the resin and concrete, that of the resinbeing about 10 times higher. Mortar composed of about 20% by weight ofresin and 80% aggregate are less of a problem in this respect. However,they nevertheless have coefficients of expansion three to five timeshigher than that of concrete in the roadway. During temperaturevariations, these differences lead to stresses at the concrete/resinmortar interface. Since concrete is the more fragile material, itgenerally cannot support these stresses. These generally producetransverse fissures, and ultimately tearing away of the surface part ofthe roadway concrete.

SUMMARY OF THE INVENTION

The main object of the present invention is to remedy these problemswhile preserving the advantages of using resin mortar in sealing thejoint. This object was achieved by two means that constitute basicelements of this invention. These means are directed at eliminating theeffects of the difference in coefficients of expansion by reducing, onthe one hand, the level of stress at the interface between resin andconcrete, and, on the other hand, by avoiding the concentration of thesestresses at particular points. In known installations which use epoxyresins, the concentration of stresses is reflected by the appearance oftransverse fissures.

In accordance with the present invention, these results are achieved bymeans of an anchorage employed with an expandable element. The anchorageincludes a gripping element which is attached securely to the expandableelement, and the gripping element in turn anchors the expandable elementto the resin mortar which is on or in the roadway. The expandableelement is an elastomeric sealing element and it can be attached to thegripping element by various means well-known to those skilled in thisart. For example, a mechanical interlock can be formed by wedging a partof the elastomeric sealing element in a grooved component attached tothe gripping element, and/or vice versa. The elastomeric sealing elementalso may be bonded by adhesive, with or without mechanical interlock,although a mechanical interlock is preferred.

The gripping element preferably is flat on the side opposite the sealingelement, and may be provided with one or more anchoring rods on thatside. In the preferred form, the anchorage includes one or moresinusoids of rods, such as concrete reinforcing rods, of diameter about6 to 12 mm. The rods extend lengthwise along the gripping element,generally parallel to the horizontal surface of the roadway so as todistribute stresses along the length of the body of resin mortar. Theypreferably are wound into a sinusoidal or spiral shape, and welded tothe surface of the gripping element opposite the elastomeric sealingelement at a succession of points. Therefore, the rods are buried in theresin mortar. The rods are cleaned, for example with abrasives, andcoated with an organic material which adheres to the resin mortar, e.g.,an epoxy paint. Preferably the gripping element is flat, e.g., one sideof a flat plate, on the side opposite the expandable element, and therods are welded to that flat surface.

These rods serve an important function in eliminating transversefissures by avoiding concentrations of stresses due to differences inexpansion between concrete and resin mortar. The reason for this effectmay be associated with the fact that the expansion coefficient of steelis close to that of concrete. Therefore, a considerable part of thestresses arising from the difference in coefficients of expansionbetween the resin mortar and the concrete can be absorbed by thereinforcement rods, and distributed by it into the resin mortar.

A further feature of the invention is the selection of a specificcategory of thermosetting resin, in the resin mortar, which exhibits agreat elasticity, even at low temperatures, less than -10° C., whileretaining good tensile strength at normal ambient temperatures such as20° to 40° C. In contrast, epoxy resins, which have desirable featuressuch as good adherence to concrete and easy use, become fragile andbrittle at low temperatures. The modulus of elasticity of a mortarobtained from epoxy resins is high at low temperatures, which results inunacceptable stresses at the interface of the road concrete and themortar. Plasticizers and diluents can be added to epoxy resins tominimize this problem, but the resistance of the resulting binder isthen insufficient to assure sealing.

Polyurethanes retain elasticity at low temperatures, and therefore,offer the potential of giving best results from this standpoint.Unfortunately, their sensitivity to moisture, both during installationand later during the life of the joint, make their use essentiallyimpossible at a site exposed to the weather.

In accordance with the present invention, a resin mortar is employedwhich contains a complex base resin containing two components and also agranular filler such as gravel or crushed stone. Great flexibility isachieved even at temperatures as low as -20° C. The resin ispolymerizable at ambient temperatures. It exhibits both the elasticityof polyurethanes and the ease of use of epoxy resins; on the other hand,it avoids the disadvantages of both of these resins. The base resinwhich makes up the essential part of the binder or sealing mortar ismade up essentially of a mixture of polyureides and epoxy resin, inproportions of 45-80% polyureide and 20-55% epoxy resin; to which may beadded diluents and plasticizers to reduce the cost and adjust thephysical characteristics.

The base resin is made at the time of installing the joints by forming aliquid mixture which is poured into place and allowed to harden. Theliquid mixture is made by combining two components, namely a component Aand a component B.

Component A is composed of

1. A liquid epoxy resin

2. A blocked polyisocyanate

3. Optionally plasticizers and diluents to reduce viscosity.

Component B is composed primarily of an aliphatic or cycloaliphaticprimary or secondary amine which will induce curing of the resinmixture, preferably at ambient or slightly elevated temperature.

BRIEF DESCRIPTION OF FIGURES OF DRAWING

In the drawing:

FIG. 1 illustrates an expansion joint in accordance with the invention,in perspective and partially in cross-section.

FIG. 2 illustrates another embodiment of an expansion joint, inaccordance with the invention, in perspective and partially incross-section.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The expansion joint illustrated in FIG. 1 comprises an expandablesealing element 1 and an anchorage comprised of steel gripping elements3 and 3¹ and a resin mortar 2. The resin mortar rests on a concreteroadway 5 which is covered with an asphalt overlay 6, to the same levelas the resin mortar 2.

The expandable sealing element 1 may be composed of a neoprene rubbercomposition which withstands low temperatures, and it may have thecross-section shown. Alternatively, it may have a variety of othercross-sections such as an upstanding arch or descending arch, or stillothers, such as those illustrated in the textbook "Expansion Joints inBridges & Roads" by Waldemar Koster (1969).

At the sides of the expandable element there are wings 7 and 7¹ whichare held by the gripping elements 3 and 3¹. Numerous constructions forthese components may be used, such as those illustrated in U.S. Pat.Nos. 3,626,822, 3,570,378 and 4,111,584, the disclosures of whichincorporated herein by reference.

The gripping elements 3 and 3¹ are illustrated with a top which is levelwith the roadway and a lower portion which rests on a layer of resinmortar. However, these are not essential requirements. For example, thegripping elements can rest directly on the concrete or be covered with alayer of resin mortar. It is desirable to have the gripping element atthe level of the roadway to provide a metal edge of the expansion gap 8,to protect the area which is struck forcefully by the wheels of vehicleswhich travel over the joint.

The gripping elements preferably have a flat surface 9 opposite from theexpandable element 1. To this surface there is welded a steel rod 4which has been formed into a spiral extending generally along the lengthof the gripping element. It will be understood that the steel rod mayhave a different shape, for example, a zig-zag shape. Also, one can useseveral straight rods, welded to the surface 9 at one end, and extendingobliquely away from that surface, but generally along the length of thegripping element so as to distribute stresses lengthwise between theresin mortar and the gripping element.

FIG. 2 illustrates another embodiment. In this case, the sealing element101 is a depending arch and the wings 107 and 107' are held between twoplates 103 and 110 which comprise the gripping elements. A bolt 111connects the plates 103 and 110 to hold the wing 107. The steel rod 104is of zig-zag shape.

The resin mortar comprises a coarse filler such as crushed stone and aresin composition made from Components A and B. Component A in turn iscomposed of two low molecular weight prepolymers, that is, a liquidepoxy resin and a polyisocyanate. The resin mortar comprises 15 to 45%by weight resin and 55 to 80% by weight of course aggregates and filler,preferably 15 to 25% by weight of resins and 75 to 85% by weight courseaggregate and filler, the proportions being chosen to give a flowableliquid mortar.

The liquid epoxy resin may in principle be of any type. Preferably it isa condensate of epichlorohydrin and a bis phenol. Particularly usefulare those resins made from a mixture of bis phenol A and bis phenol F,as these will tend to provide a lower viscosity product. The epoxyequivalent weight of such a polymer is preferably of the order of180-200. Typical commercial epoxy resins which may be used are Epikote828, Shell DX 214, Versamidle 140 of Schering and Dow DER 74.75.

The polyisocyanate constituent is a blocked polyisocyanate which may bea prepolymer of a simple polyisocyanate with a polyether. Thepolyisocyanate constituent is selected so that, in unblocked form, itcontains about 2-6% free isocyanate groups. It may be made from a simplepolyisocyanate such as tolylene diisocyanate, diphenyl methanediisocyanate, or mixtures of the latter with low molecular weightpolyphenylene polymethylene polyisocyanates known as crude MDI or PAPI.The polyether preferably is polyoxypropylene glycol, polyoxybutyleneglycol or a copolymer of propylene oxide and/or butylene oxide withethylene oxide. Polyoxyethylene glycols themselves tend to impartmoisture sensitivity to the composition and therefore are less suitable.Polymers of propylene oxide or butylene oxide with a triol or higherpolyol is less desirable because they tend to increase viscosity,although a small amount may be present. Molecular weights of 600 to 2500are suitable for the polyether. It is possible also to employ polyestersto make the polyisocyanate constituent. However, such materials tend tobe more sensitive to moisture and therefore are less desirable. Theproportions of simple polyisocyanate and polyether are chosen so thatthe polyisocyanate prepolymer contains about 2-6% free isocyanategroups. Also, the constituents should be selected for low viscosity,preferably in the range of 20,000 to 150,000 centipoises at 20° C.

The polyisocyanate prepolymer is employed with the isocyanate groupsblocked with a phenol in known manner. Suitable phenols include phenol,cresols, tertiary butyl phenol and nonyl phenol.

Component A may also include a small amount of plasticizer and/ordiluent. Examples of such materials include butyl phthalate, octylphthalate, the Shell aromatic plasticizer Dutrex and others. Thesematerials are added to reduce viscosity, but, if used in excess, maypermanently soften the product.

The proportions of the respective constituents of component A may be asfollows:

20 to 50 parts liquid epoxy resin

50 to 80 parts blocked polyisocyanate prepolymer

3 to 20% of the resin portion of the resin mortar of plasticizer ordiluent, if that constituent is used.

Component B contains, as its essential ingredient, an aliphatic orcycloaliphatic polyamine comprised of primary or secondary amine groups.This constituent should be chosen to unblock the polyisocyanateconstituent, and to react with it to form polyureide while at the sametime curing the epoxy resin, at room temperature or at slightly elevatedtemperature which can be created at the job site. Suitable polyaminesinclude trimethylhexamethylene diamine, aminoethylpiperazine,bis-aminocyclohexylmethane and 3,3'-dimethyl 4,4'diaminodicyclohexylmethane.

The polyamine is used in amounts which are approximately stoichiometricwith the total of reactive groups in the epoxy resin and thepolyisocyanate prepolymer. This generally requires about 7 to 20% of thetotal weight of epoxy resin and polyureide which is formed.

Component B may also contain diluents which reduce the cost of thebinder and reduce viscosity at the time the components are mixed.Diluents also improve the wetting of the coarse aggregates and theconcrete roadway. Preferred diluents are coal tar pitch of viscositybetween 10 and 40 EVT, or coumarone or coumarone indene resins such asthat sold under the name Nacirea EPXL by Cindu Neuville Chimie, orothers. Diluents which react with the constituents of component A mayalso be used.

Such diluents generally are added to Component B at a rate of 10% to100% of the total of epoxy resin and polyureide to be formed with theuse of such diluents.

The coarse aggregate may be gravel, coarse stone, or the like. Forexample, it may have a standard continuous particle size distributioncurve between 0.08 and 15 mm. having 30-65% which passes a 2 mm. screen,12-15% passing an 0.08 mm. screen and 100% passing a 15 mm. screen.

Installation of the joint according to the invention is rather simple.The sealing element 1 and the metal components of the anchorage may befabricated at a factory and delivered at a site. Ledges are provided inthe concrete roadway as shown in the drawing, and the concrete iscleaned and free of any debris. The assembly of sealing element andanchorage components is set into place on the ledges and the width ofthe joint is set in conventional fashion. Components A and B arecombined and mixed with the coarse aggregate, although the latter maypreviously be combined with one of the resin components. Then the resinmortar is poured into place where it adheres to the metal components andthe concrete. Preferably, if an asphalt overlay is to be used, in lieuof ledges formed in the concrete, it is laid against a dam before thejoint is installed, so that the resin mortar will adhere to the asphalt.

The binder for the coarse filler which is obtained from theabove-described resin composition has unique qualities. These qualitiescan be evaluated by tensile-elongation tests, which reveal substantialimprovement over a standard epoxy resin.

A typical resin composition which may be made up of 50% polyureideobtained by reaction of a tolylene diisocyanate polyether prepolymerhaving 3% isocyanate groups, 20% DX 214 epoxy resin,3,3'-dimethyl-4,4'-diaminodicyclohexylmethane reacted with theprepolymer and epoxy resin in stoichiometric amount (proportion includedin proportions of resins), 30% coal tar pitch of EVT 30. The propertiesof such a material, compared with a standard epoxy resin, are asfollows:

at 20° C. elongation is:

(a) 30-45% for the standard epoxy resin

(b) more than 200% for the binder of the present invention.

tensile strength is:

(a) 30 to 45 bars for the epoxy resin

(b) about 45 bars for the binder of the present invention.

at -15° C. elongation is:

(a) nearly 0% for the epoxy resin

(b) greater than 100% for the binder of the present invention.

tensile strength is:

(a) greater than 300 kg for the epoxy resin

(b) between 100 and 150 bars for the binder of the present invention.

It can be seen that the stresses transmitted to the concrete pavementwill be much less for the composition of the present invention.

A specific example of the composition is as follows:

Component A

30 parts of Dow DER 74.75 epoxy resin

70 parts of liquid isocyanate prepolymer having an average molecularweight of 2,000, containing 3% free isocyanate groups, obtained byreaction of tolylene diisocyanate on polypropylene glycol, using anexcess of tolylene diisocyanate, blocked with phenol.

5 parts butyl phthalate.

Component B

15 pars 3,3'-dimethyl-4,4'-diaminodicyclo-hexylmethane

50 parts coal tar pitch of 30 EVT viscosity

When Components A and B have been mixed, and they have polymerized(which polymerization can be accelerated by heating, the resin obtainedhas the following characteristics:

at 20° C.:

tensile strength 40-50 bars

elongation more than 150%

at -15° C.:

tensile strength 100 to 150 bars

elongation more than 100%

The mortar can be made from a mixture of 17% of this composition and 83%aggregate sized in the range 0 to 13 mm. Before polymerization, it islike a viscous paste that strongly adheres to the roadway concrete, thesides of the joint and the asphalt. The material can be tested bypouring the mixture to form a coating having a thickness of 3 mm on aslab of concrete 10×50 cm. If a series of thermal shock tests areperformed between -40° C. and +20° C., neither delamination nor ruptureof the concrete occurs. If standard epoxy resin is substituted for theresin of the present invention, rupture of the concrete occurs.

What is claimed is:
 1. An expansion joint for a concrete roadway or thelike comprising an expandable sealing element, a resin mortar comprisedof coarse aggregate and a resin composition and means anchoring theexpandable sealing element to the resin mortar, said resin compositioncomprising a mixture of epoxy resin and polyureide.
 2. An elastomericexpansion joint as set forth in claim 1 in which said anchoring meanscomprises a generally flat surface and one or more rods extending fromsaid flat surface in a direction generally lenthwise along the joint,said rods being embedded in said resin motar.
 3. An elastomericexpansion joint as set forth in claim 2 in which said flat surface issubstantially vertical and said one or more rods extend from said flatsurface laterally outwardly from said expandable sealing element andgenerally lengthwise along the joint.
 4. An elastomeric joint as setforth in claim 3 in which said one or more rods comprise a sinusoid,said sinusoid being attached to said flat surface at a plurality ofpoints along the length of the joint.
 5. An elastomeric sealing elementas set forth in claim 4 in which said sinusoid is metal.
 6. An expansionjoint as set forth in claim 2 in which said resin mortar comprises 15 to45% of said resin composition and 55 to 85% of said coarse aggregate. 7.An expansion joint as set forth in claim 2 in which said resin mortarcomprises 15 to 25% of said resin composition and 75 to 85% of saidcoarse aggregate.
 8. An expansion joint as set forth in claim 2 in whichthe coarse aggregate comprises a mixture of aggregates and sand.
 9. Anexpansion joint as set forth in claim 2 in which said resin compositioncomprises 45 to 80% polyureide and 20 to 55% of epoxy resin, thepercentages being based on the total of polyureide and epoxy resin. 10.An expansion joint as set forth in claim 8 in which said resincomposition also contains plasticizer and/or diluent.
 11. An expansionjoint as set forth in claim 2 in which the resin is obtained by reactionof Component A and Component B, wherein Component A is a mixture of(1) aliquid polyisocyanate prepolymer containing 2 to 6% of NCO groupsblocked by a phenol (2) an epoxy resin and Component B comprises analiphatic or cycloaliphatic diamine.
 12. An concrete roadway having agap thereon, and an expansion joint according to claim 1 covering oversaid gap, the resin mortar adhering said anchoring means to the roadway.